EV Battery Replacement Relay Control to Prevent Connector Arcing
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Solution Overview
Problem
The risk of arc discharge occurring in a battery connector during battery replacement in electric vehicles due to vehicle activation operations and the potential for unnecessary battery replacement procedures or machine operation failures.
Innovation Solution
A control system with a vehicle ECU, ignition power source, battery replacement switch, and first relay that electrically cuts off the circuit during battery replacement to prevent vehicle activation, using safety and hold relays to ensure safe battery replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the system main relay is switched on when a vehicle activation operation is performed, then the vehicle is made ready for traveling, but arc discharge may occur in the battery connector during battery replacement causing component damage
Solution Approach 1:
The control system performs preliminary detection of the battery replacement switch state before activating the vehicle. When the battery replacement switch is detected to be on, the system preemptively prevents the system main relay from switching on, thereby avoiding arc discharge in the battery connector before it can occur
Solution Approach 2:
The battery replacement switch acts as an intermediary control element between the user's activation operation and the system main relay. The vehicle ECU monitors this intermediary switch and uses its state to mediate whether the system main relay should be activated, preventing direct connection that would cause arc discharge
2Reliability
If the ECU notifies the battery replacement station of an emergency stop command during battery replacement, then danger is avoided, but unnecessary battery replacement procedures are redone or machine operation failures occur
Solution Approach 1:
The system performs preliminary detection of the battery replacement switch state before executing vehicle activation or emergency stop commands. By checking the switch state in advance, the system can distinguish between intentional battery replacement operations and accidental activation, thereby avoiding unnecessary emergency stop notifications and procedure redos
Solution Approach 2:
The vehicle ECU continuously monitors the state of the battery replacement switch and uses this feedback information to determine appropriate system responses. When the switch is on during activation attempts, the system feedback loop prevents erroneous emergency stop commands, ensuring that battery replacement procedures are not unnecessarily interrupted
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Prevents arc discharge and ensures safe battery replacement by preventing vehicle activation during the process, avoiding component damage and operation failures.
Implementation Method 1
a first relay that is disposed in an electric circuit connecting between the ignition power source and the vehicle ECU, so as to be in conjunction with an on/off state of the battery replacement switch, and that electrically cuts off the electric circuit while the battery replacement switch is in the on state
Data Source
AI summary
Control system Cu for electric vehicle C according to the present disclosure includes: vehicle ECU 202; ignition power source E1 that starts power supply to vehicle ECU 202 in response to a vehicle activation operation by a user; battery replacement switch 101 that receives a replacement command operation for battery 11 from the user; and first relay 203 that is disposed in electric circuit L1 connecting between ignition power source E1 and vehicle ECU 202, so as to be in conjunction with an on/off state of battery replacement switch 101, and that electrically cuts off electric circuit L1 while battery replacement switch 101 is in the on state.